Intelligent operation control system of oilless vacuum pump

Abstract

The invention relates to the technical field of oilless vacuum pump operation control systems, and discloses an intelligent operation control system of an oilless vacuum pump. The intelligent control system comprises a sensor and data acquisition module, a data storage and transmission module, a data analysis and fault diagnosis module, an operation optimization and control module, a user interface and visualization module, a predictive maintenance module, a safety protection module and a remote monitoring and cloud platform. By means of the system, manpower, material resources and time cost needed by maintenance can be reduced, the stability of equipment operation can be improved, and cost can be reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of oil-free vacuum pump operation control systems, and in particular relates to an intelligent operation control system for an oil-free vacuum pump. Background Art

[0002] An oil-free vacuum pump is a mechanical vacuum pump that does not require any oil for lubrication. The working principle of an oil-free vacuum pump is to continuously change the volume on both sides of the pump body through the eccentric rotation of the rotor. The volume on one side expands to inhale gas, while the volume on the other side decreases to exhaust gas, thereby completing the intake and exhaust of gas and achieving vacuum.

[0003] The oil-free vacuum pump industry is no exception. To improve production efficiency, optimize resource allocation, and reduce operating costs, traditional oil-free vacuum pump operation control systems are gradually becoming inadequate, necessitating a shift toward intelligent operation control systems. Intelligent control systems monitor the equipment's operating status in real time and automatically adjust operating parameters based on changing operating conditions, enabling more efficient and stable production. While intelligent operation control systems have been implemented to some extent in the oil-free vacuum pump industry, the integration and application of predictive maintenance technology, a higher-level intelligent capability, is still in the development stage.

[0004] To this end, we propose an intelligent operation control system for an oil-free vacuum pump. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent operation control system for an oil-free vacuum pump in order to improve the stability of equipment operation and reduce costs.

[0006] The technical solution adopted in the present invention is as follows: An intelligent operation control system for an oil-free vacuum pump, comprising a sensor and data acquisition module, a data storage and transmission module, a data analysis and fault diagnosis module, an operation optimization and control module, a user interface and visualization module, a predictive maintenance module, a safety protection module, and a remote monitoring and cloud platform; The sensor and data acquisition module monitors the operating status of the equipment in real time through a variety of sensors, and converts these status data into usable information for use by the data analysis and fault diagnosis module and the operation optimization and control module; The data storage and transmission module is used to store and transmit data collected by sensors. The data can be stored in the local device for real-time analysis, or uploaded to the cloud to support remote monitoring and big data analysis. The data analysis and fault diagnosis module is used to analyze the collected data, determine the equipment status and diagnose faults, and make fault judgments based on the thresholds of vibration, temperature and pressure; The operation optimization and control module is used to optimize the equipment operating parameters according to the analysis results and realize automatic control. It can adjust the motor speed and valve opening parameters according to real-time data, and can also reduce energy consumption by adjusting the speed and pressure setting values. It automatically adjusts the operation mode according to load changes and realizes load balancing and coordinated operation in the multi-pump system. The user interface and visualization module is used to provide users with visual information and operation interface of device status; The predictive maintenance module is used to predict equipment failures based on data analysis, formulate maintenance plans, predict the remaining life of key components through predictive assessment models, remind users to perform maintenance based on the prediction results, and record maintenance history to facilitate subsequent optimized maintenance; The safety protection module is used to monitor the motor current, temperature and vacuum pressure of the oil-free vacuum pump and automatically shut down the pump in case of serious failure to avoid equipment damage; The remote monitoring and cloud platform is used to remotely monitor and manage the equipment, remotely adjust equipment parameters or start and stop equipment through the cloud platform, and simultaneously monitor and manage multiple oil-free vacuum pumps.

[0007] In a preferred embodiment of the invention, the sensor and data acquisition module includes a vibration sensor, a temperature sensor, a pressure sensor, a current sensor, a noise sensor and a flow sensor, so as to collect the operating data of the oil-free vacuum pump in real time.

[0008] In a preferred embodiment of the invention, the vibration sensor is used to monitor the vibration intensity of the pump and determine the status of bearings or mechanical parts; the temperature sensor is used to monitor the temperature of the motor, pump body and environment to prevent overheating; the pressure sensor is used to monitor the vacuum pressure to ensure that the pump operates within the set range; the current sensor is used to monitor the motor current to determine the load status and motor health; the noise sensor is used to detect abnormal noise and assist in fault judgment; the flow sensor is used to monitor gas flow and optimize operating efficiency.

[0009] In a preferred embodiment of the invention, the communication protocols of the data storage and transmission module include Modbus, Ethernet, Wi-Fi, Bluetooth, LoRa and 4G / 5G communication.

[0010] In a preferred embodiment of the invention, the visual information and operation interface include an HMI human-machine interface and an APP interface.

[0011] In a preferred embodiment of the invention, the HMI human-machine interface is used to implement a local touch screen or control panel to display real-time data and operating status.

[0012] In a preferred embodiment of the invention, the APP interface is used to support remote monitoring and operation, and provide data visualization graphs and dashboards.

[0013] In a preferred embodiment of the invention, the prediction model algorithm of the predictive maintenance module is: model = Sequential() model.add(LSTM(50,input_shape=(X_train.shape[1],X_train.shape[2]))) model.add(Dense(1)) model.compile(optimizer="adam", loss="mse") model.fit(X_train,y_train,epochs=20,batch_size=32,validation_data=(X_test, y_test)) y_pred = model.predict(X_test) From sklearn.metrics import mean_squared_error, mean_absolute_error mse = mean_squared_error(y_test, y_pred) mae = mean_absolute_error(y_test, y_pred) print(f"MSE: {mse}, MAE: {mae}").

[0014] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. In the present invention, by real-time monitoring of the operating status of key components of the oil-free vacuum pump and using a predictive maintenance module to predict their remaining lifespan, potential faults can be discovered in a timely manner to avoid production interruptions caused by sudden equipment failures. Operation and maintenance personnel can also arrange maintenance work more accurately, avoiding unnecessary downtime and excessive maintenance. This not only reduces the manpower, material resources, and time costs required for maintenance, but also helps to improve the stability of equipment operation and reduce costs.

[0015] 2. In the present invention, a predictive model is used to predict the lifespan of key components of the oil-free vacuum pump, so that operation and maintenance personnel can formulate maintenance plans in advance based on the prediction results, implement preventive maintenance measures, and regularly inspect and replace wearing parts. This can significantly reduce the equipment failure rate and component damage caused by failures, thereby extending the service life of the oil-free vacuum pump and its key components, helping to improve the stability of equipment operation and reduce costs.

[0016] 3. In the present invention, through the user interface and visualization module as well as the remote monitoring and cloud platform, operators can more accurately control the operating status of the oil-free vacuum pump to ensure that it always maintains the best working condition; the remote monitoring and cloud platform can not only monitor the operating status of the oil-free vacuum pump in real time, but also predict the maintenance needs of the equipment through data analysis, so that operators can perform maintenance in advance, reducing downtime and repair costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a system diagram of the present invention. DETAILED DESCRIPTION

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0019] The following will be combined Figure 1 An intelligent operation control system of an oil-free vacuum pump according to an embodiment of the present invention is described in detail. Example

[0020] Reference Figure 1, an intelligent operation control system for an oil-free vacuum pump, the intelligent control system includes a sensor and data acquisition module, a data storage and transmission module, a data analysis and fault diagnosis module, an operation optimization and control module, a user interface and visualization module, a predictive maintenance module, a safety protection module and a remote monitoring and cloud platform. The sensor and data acquisition module monitors the operating status of the equipment in real time through a variety of sensors, and converts these status data into usable information for use by the data analysis and fault diagnosis module and the operation optimization and control module; the sensor and data acquisition module includes a vibration sensor, a temperature sensor, a pressure sensor, a current sensor, a noise sensor and a flow sensor, so as to collect the operating data of the oil-free vacuum pump in real time; the vibration sensor is used to monitor the vibration intensity of the pump and judge the status of the bearings or mechanical parts; the temperature sensor is used to monitor the motor, pump Abnormal vibration data may indicate bearing wear or mechanical looseness, abnormal temperature data may indicate motor overheating or cooling system failure, and abnormal pressure data may indicate seal leakage or decreased pump efficiency, so that the motor speed can be adjusted according to the pressure data to maintain the set vacuum pressure, and the working state of the cooling system can be adjusted according to the temperature data to prevent overheating, and the vibration data can be used to determine whether the load needs to be reduced or the machine needs to be shut down for maintenance.

[0021] Reference Figure 1 The data storage and transmission module is used to store and transmit data collected by sensors. The data can be stored in the local device for real-time analysis, or the data can be uploaded to the cloud to support remote monitoring and big data analysis. The communication protocols of the data storage and transmission module include Modbus, Ethernet, Wi-Fi, Bluetooth, LoRa and 4G / 5G communication. Specifically, the data storage and transmission module can record various parameters and status information during the operation of the oil-free vacuum pump, such as temperature, pressure, and vibration. These data can be retrieved and analyzed at any time after storage. It is also responsible for transmitting the collected data to the central console or cloud server, so that operators can view the operating status of the oil-free vacuum pump in real time through the Internet at a location far away from the equipment site. Once the equipment fails or is abnormal, the operator can respond quickly and perform remote diagnosis and processing, thereby shortening downtime and improving equipment reliability and availability.

[0022] Reference Figure 1The data analysis and fault diagnosis module is used to analyze the collected data, judge the equipment status and diagnose faults, and make fault judgments based on the thresholds of vibration, temperature, and pressure. The operation optimization and control module is used to optimize the equipment operation parameters according to the analysis results and realize automatic control. The motor speed and valve opening parameters can be adjusted according to real-time data, and energy consumption can be reduced by adjusting the speed and pressure setting values. The operation mode is automatically adjusted according to load changes to achieve load balancing and coordinated operation in the multi-pump system. Specifically, by real-time monitoring of the operating status of key components of the oil-free vacuum pump and using the predictive maintenance module to predict its remaining life, potential faults can be discovered in time to avoid production interruptions caused by sudden equipment failures. Operation and maintenance personnel can also arrange maintenance work more accurately to avoid unnecessary downtime and excessive maintenance. It can not only reduce the manpower, material and time costs required for maintenance, but also help improve the stability of equipment operation and reduce costs.

[0023] Reference Figure 1 , the prediction model algorithm of the predictive maintenance module is: model = Sequential() model.add(LSTM(50,input_shape=(X_train.shape[1],X_train.shape[2]))) model.add(Dense(1)) model.compile(optimizer="adam", loss="mse") model.fit(X_train,y_train,epochs=20,batch_size=32, validation_data=(X_test, y_test)) y_pred = model.predict(X_test) From sklearn.metrics import mean_squared_error, mean_absolute_error mse = mean_squared_error(y_test, y_pred) mae = mean_absolute_error(y_test, y_pred) Specifically, a prediction model is used to predict the lifespan of key components of oil-free vacuum pumps. This allows operation and maintenance personnel to formulate maintenance plans in advance based on the prediction results, implement preventive maintenance measures, and regularly inspect and replace wearing parts. This can significantly reduce equipment failure rates and component damage caused by failures, thereby extending the service life of oil-free vacuum pumps and their key components, improving equipment operation stability and reducing costs.

[0024] Reference Figure 1 The user interface and visualization module is used to provide users with visual information and operation interface of the equipment status; the visual information and operation interface includes HMI human-machine interface and APP interface. The HMI human-machine interface is used to realize local touch screen or control panel to display real-time data and operating status. The APP interface is used to support remote monitoring and operation, and provide data visualization curve charts and dashboards; the safety protection module is used to monitor the motor current, temperature and vacuum pressure of the oil-free vacuum pump, and automatically shut down in case of serious faults to avoid equipment damage; the remote monitoring and cloud platform is used to remotely monitor and manage the equipment, remotely adjust equipment parameters or start and stop equipment through the cloud platform, and monitor and manage multiple oil-free vacuum pumps at the same time; specifically, through the user interface and visualization module and the remote monitoring and cloud platform, operators can more accurately control the operating status of the oil-free vacuum pump to ensure that it always maintains the best working condition; the remote monitoring and cloud platform can not only monitor the operating status of the oil-free vacuum pump in real time, but also predict the maintenance needs of the equipment through data analysis, so that operators can perform maintenance in advance, reducing downtime and maintenance costs.

[0025] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of other identical elements in the process, method, article, or device comprising the element.

[0026] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. An intelligent operation control system for an oil-free vacuum pump, characterized by: The intelligent control system includes a sensor and data acquisition module, a data storage and transmission module, a data analysis and fault diagnosis module, an operation optimization and control module, a user interface and visualization module, a predictive maintenance module, a safety protection module and a remote monitoring and cloud platform; The sensor and data acquisition module monitors the operating status of the equipment in real time through a variety of sensors, and converts these status data into usable information for use by the data analysis and fault diagnosis module and the operation optimization and control module; The data storage and transmission module is used to store and transmit data collected by sensors. The data can be stored in the local device for real-time analysis, or uploaded to the cloud to support remote monitoring and big data analysis. The data analysis and fault diagnosis module is used to analyze the collected data, determine the equipment status and diagnose faults, and make fault judgments based on the thresholds of vibration, temperature and pressure; The operation optimization and control module is used to optimize the equipment operating parameters according to the analysis results and realize automatic control. It can adjust the motor speed and valve opening parameters according to real-time data, and can also reduce energy consumption by adjusting the speed and pressure setting values. It automatically adjusts the operation mode according to load changes and realizes load balancing and coordinated operation in the multi-pump system. The user interface and visualization module is used to provide users with visual information and operation interface of device status; The predictive maintenance module is used to predict equipment failures based on data analysis, formulate maintenance plans, predict the remaining life of key components through predictive assessment models, remind users to perform maintenance based on the prediction results, and record maintenance history to facilitate subsequent optimized maintenance; The safety protection module is used to monitor the motor current, temperature and vacuum pressure of the oil-free vacuum pump and automatically shut down the pump in case of serious failure to avoid equipment damage; The remote monitoring and cloud platform is used to remotely monitor and manage the equipment, remotely adjust equipment parameters or start and stop equipment through the cloud platform, and simultaneously monitor and manage multiple oil-free vacuum pumps.

2. The intelligent operation control system of an oil-free vacuum pump according to claim 1, characterized in that: The sensor and data acquisition module includes a vibration sensor, a temperature sensor, a pressure sensor, a current sensor, a noise sensor and a flow sensor, so as to collect the operating data of the oil-free vacuum pump in real time.

3. The intelligent operation control system of an oil-free vacuum pump according to claim 2, characterized in that: The vibration sensor is used to monitor the vibration intensity of the pump and determine the status of bearings or mechanical components; the temperature sensor is used to monitor the temperature of the motor, pump body and environment to prevent overheating; the pressure sensor is used to monitor the vacuum pressure to ensure that the pump operates within the set range; the current sensor is used to monitor the motor current to determine the load status and motor health; the noise sensor is used to detect abnormal noise and assist in fault judgment; the flow sensor is used to monitor gas flow and optimize operating efficiency.

4. The intelligent operation control system of an oil-free vacuum pump according to claim 1, characterized in that: The communication protocols of the data storage and transmission module include Modbus, Ethernet, Wi-Fi, Bluetooth, LoRa and 4G / 5G communication.

5. The intelligent operation control system of an oil-free vacuum pump according to claim 1, characterized in that: The visual information and operation interface includes an HMI human-machine interface and an APP interface.

6. The intelligent operation control system of an oil-free vacuum pump according to claim 5, characterized in that: The HMI human-machine interface is used to implement a local touch screen or control panel to display real-time data and operating status.

7. The intelligent operation control system of an oil-free vacuum pump according to claim 5, characterized in that: The APP interface is used to support remote monitoring and operation, and provide data visualization graphs and dashboards.

8. The intelligent operation control system of an oil-free vacuum pump according to claim 1, characterized in that: The prediction model algorithm of the predictive maintenance module is: model = Sequential() model.add(LSTM(50,input_shape=(X_train.shape[1],X_train.shape[2]))) model.add(Dense(1)) model.compile(optimizer="adam", loss="mse") model.fit(X_train, y_train, epochs=20, batch_size=32, validation_data=(X_test, y_test)) y_pred = model.predict(X_test) From sklearn.metrics import mean_squared_error, mean_absolute_error mse = mean_squared_error(y_test, y_pred) mae = mean_absolute_error(y_test, y_pred) print(f"MSE: {mse}, MAE: {mae}").

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